KTM 525 XC ATV 2008 User manual

OWNER'S MANUAL 2008
450 XC ATV
525 XC ATV
ART. NO. 3211251en

DEAR KTM CUSTOMER 1
'($5 .70 &86720(5
Congratulations on your decision to buy a KTM ATV. You are now the owner of a state-of-the-art sports ATV that will give you enormous
pleasure if you service and maintain it accordingly.
We wish you great pleasure riding the vehicle!
Enter the serial numbers of your vehicle below.
Chassis number ( P. 12) Dealer's stamp
Engine number ( P. 12)
Key number ( P. 12)
The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing
development and design can however not be completely excluded.
All specifications are not binding. KTM Sportmotorcycle AG in particular reserves the right to modify or delete technical specifica-
tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as printing and other errors. The models portrayed partly contain special
equipment that does not belong to the regular scope of delivery.
© 2007 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, is permitted only with the express written permission of the copyright owner.
ISO 9001(12 100 6061)
Within the meaning of the international quality management standard ISO 9001, KTM uses quality assurance processes
that lead to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria

CONTENTS 2
&217(176
MEANS OF REPRESENTATION ............................................ 4
IMPORTANT NOTES............................................................ 5
Overview of warning labels................................................ 8
VIEW OF VEHICLE............................................................. 10
Vehicle view, front left ................................................... 10
View of vehicle, rear right ............................................... 11
LOCATION OF SERIAL NUMBERS ...................................... 12
Chassis number............................................................. 12
Type label..................................................................... 12
Key number .................................................................. 12
Engine number.............................................................. 12
Setting number, front shock absorber .............................. 12
Setting number, rear shock absorber ............................... 13
OPERATING ELEMENTS.................................................... 14
Clutch lever .................................................................. 14
Reverse gear release lever .............................................. 14
Hand brake lever, parking brake...................................... 14
Throttle lever................................................................. 14
Light switch.................................................................. 15
ENG.bSTOPbSwitch ........................................................ 15
Electric starter button .................................................... 15
Ignition switch .............................................................. 15
Indicator lamp overview ................................................. 15
Emergency OFF switch with rip cord................................ 16
Opening filler cap.......................................................... 16
Closing filler cap ........................................................... 16
Fuel tap........................................................................ 16
Choke........................................................................... 17
Hot start button............................................................. 17
Shift lever..................................................................... 17
Foot brake pedal ........................................................... 17
TIPS ON PUTTING INTO OPERATION ................................. 18
Advice on first use......................................................... 18
Running in the engine.................................................... 19
RIDING INSTRUCTIONS .................................................... 20
Checks before putting into operation ............................... 20
Starting ........................................................................ 20
Starting up ................................................................... 21
Shifting ........................................................................ 21
shifting to reverse gear................................................... 22
Disengaging reverse gear ................................................ 22
Braking ........................................................................ 22
Riding .......................................................................... 23
Riding in bends............................................................. 23
Riding downhill ............................................................. 24
Riding uphill................................................................. 24
Riding perpendicular to the slope.................................... 25
Turning on slopes .......................................................... 25
Riding through water ..................................................... 25
Switching off the engine ................................................ 26
Stopping, parking .......................................................... 26
Refueling...................................................................... 27
GREASING AND SERVICE TABLE ....................................... 28
Important maintenance work to be carried out by an
authorized KTM workshop. ............................................. 28
Important maintenance work to be carried out by an
authorized KTM workshop. (as additional order)................ 29
Important checks and maintenance work to be carried
out by the rider. ............................................................ 29
MAINTENANCE ON CHASSIS AND ENGINE ........................ 31
Jacking up the vehicle ................................................... 31
Removing the vehicle from the work stand ....................... 31
Basic information on changing the chassis settings........... 31
Adjusting front shock absorber compression damping ....... 31
Adjusting front shock absorber rebound damping.............. 32
Adjusting front shock absorber cross over......................... 33
Adjusting front shock absorber spring preload .................. 33
Adjusting rear shock absorber compression damping......... 34
Adjusting rear shock absorber rebound damping ............... 35
Adjusting rear shock absorber spring preloadbx............... 36
Removing the rear shock absorberbx.............................. 37
Installing the rear shock absorberbx............................... 37
Toe, checkingbx........................................................... 37
Adjusting the toebx...................................................... 38
Checking/adjusting camberbx........................................ 40
Fork offset .................................................................... 41
Adjusting the fork offsetbx............................................ 41
Toe width of rear axle..................................................... 41
Adjusting the toe width of rear axlebx............................. 41
Handlebar position ........................................................ 42
Adjusting handlebar positionbx...................................... 43
Checking play in gas Bowden cable ................................. 43
Adjusting play in gas Bowden cable................................. 44
Checking the play in the Bowden cable using the reverse
gear release lever........................................................... 44
Adjusting the play in the Bowden cable using the reverse
gear release lever........................................................... 44
Checking chain dirt ....................................................... 45
Cleaning the chain......................................................... 45
Checking the chain tension ............................................ 45
Checking rear sprocket / engine sprocket for wear ............. 45
Checking chain wear...................................................... 46
Adjusting chain tension.................................................. 46
Greasing the rear wheel eccentric element ....................... 47
Checking brake discs ..................................................... 47
Checking free play of hand brake lever............................. 48
Adjusting basic position of handbrake lever...................... 48
Checking front brake fluid level....................................... 48
Topping up the front brake fluidbx................................. 49
Checking the front brake linings...................................... 49
Removing front brake liningsbx...................................... 50
Mounting front brake liningsbx...................................... 50
Changing the front brake liningsbx................................. 51
Checking free play of foot brake lever .............................. 52
Adjusting basic position of footbrake leverbx................... 52
Checking rear brake fluid level........................................ 52
Topping up brake fluid of front brakebx.......................... 53
Checking rear brake linings ............................................ 54
Removing rear brake liningsbx....................................... 54
Mounting rear brake liningsbx....................................... 55
Changing rear brake liningsbx........................................ 55
Removing wheel/wheels.................................................. 56
Mounting wheel/wheels .................................................. 56
Tire condition checking.................................................. 57
Checking tire air pressure............................................... 57
Removing the battery..................................................... 57
Installing the battery...................................................... 58
Recharging the batterybx.............................................. 58
changing main fuse ....................................................... 59
Changing the fuses of individual power-consuming
components .................................................................. 59
Ignition curve plug connection........................................ 60
Changing ignition curve.................................................. 61

CONTENTS 3
Removing the seat ......................................................... 61
Mounting the seat ......................................................... 61
Removing the radiator spoiler ......................................... 61
Installing the radiator spoiler .......................................... 62
Removing the front cover................................................ 62
Installing the front cover ................................................ 62
Removing the front trim ................................................. 63
Installing the front trim .................................................. 63
Removing the rear fender ............................................... 63
Installing the rear fender ................................................ 64
Removing the engine guard ............................................ 65
Installing the engine guard ............................................. 65
Removing the air filterbx............................................... 65
Installing the air filterbx............................................... 66
Cleaning air filterbx...................................................... 66
Adjusting basic position of clutch lever............................ 66
Checking fluid level of hydraulic clutch ........................... 66
Cooling system.............................................................. 67
Radiator fan.................................................................. 67
Checking antifreeze and coolant level .............................. 67
Checking the coolant level.............................................. 68
Draining coolantbx....................................................... 68
Filling coolant / bleeding cooling systembx..................... 69
Carburetor - idle ............................................................ 70
Carburetor - adjusting idlebx......................................... 71
Emptying the carburetor float chamberbx....................... 72
Checking engine oil level................................................ 72
Changing engine oil and oil filter, cleaning oil
screensbx.................................................................... 73
Draining engine oil, cleaning oil screensbx..................... 73
Removing the oil filterbx............................................... 74
Mounting oil filterbx..................................................... 75
Filling up with engine oilbx........................................... 75
Topping up engine oil .................................................... 76
TROUBLESHOOTING......................................................... 77
CLEANING........................................................................ 79
Cleaning the vehicle ...................................................... 79
STORAGE ......................................................................... 80
Storage......................................................................... 80
Putting the vehicle into operation after storage................. 80
TECHNICAL DATA - ENGINE.............................................. 81
Capacity - engine oil ...................................................... 81
Capacity - cooling liquid................................................. 82
TECHNICAL DATA - ENGINE TIGHTENING TORQUES.......... 83
TECHNICAL DATA - CARBURETOR..................................... 85
450/525bXCbATV ........................................................... 85
TECHNICAL DATA - CHASSIS ............................................ 86
Lighting equipment ....................................................... 87
Tires ............................................................................ 87
Capacity - fuel............................................................... 87
TECHNICAL DATA - FRONT SHOCK ABSORBER.................. 88
TECHNICAL DATA - REAR SHOCK ABSORBER.................... 89
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ........ 90
WIRING DIAGRAM ............................................................ 92
450/525bXCbATV ........................................................... 92
SUBSTANCES................................................................... 95
AUXILIARY SUBSTANCES.................................................. 97
STANDARDS..................................................................... 98
INDEX .............................................................................. 99

MEANS OF REPRESENTATION 4
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Symbols used
The symbols used are explained in the following.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of
your own safety, have these jobs done in an authorized KTM workshop! There, your vehicle will be serviced opti-
mally by specially trained experts using the specialist tools required.
Identifies a page reference (more information is provided on the specified page).
Formats used
The typographical and other formats used are explained in the following.
Specific name Identifies a specific name.
Name®Identifies a protected name.
Brand™ Identifies a brand in merchandise traffic.

IMPORTANT NOTES 5
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Use definition
KTM ATVs are designed and built to withstand the normal stresses and strains of competitive use. The vehicles comply with currently
valid regulations and categories of the top international motorsport organizations.
Warning
Danger of accidentsಘIncorrect assessment of riding situations.
ದThe vehicle may only be ridden by persons over the age of 16.
Info
The ATV must be used only on secluded property remote from public road traffic.
The ATV is designed for off-road sport endurance competition (Enduro) and not for the predominant motocross use.
Maintenance
A prerequisite for perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work described
in the owner's manual are properly carried out. Poor adjustment and tuning of the engine and chassis can lead to damage and break-
age of components.
Using the vehicle in extreme conditions such as very muddy or wet terrain can lead to above-average wear of components such as the
transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the
greasing and service table is reached.
Pay careful attention to the prescribed running-in period, inspection and maintenance intervals. If you observe these exactly, you will
ensure a much longer service life for your vehicle.
Warranty
The maintenance work prescribed in the greasing and service table must be carried out in an authorized KTM workshop and confirmed
in the customer's service record, since otherwise no warranty claims will be recognized. No warranty claims can be considered for
damage resulting from manipulations and alterations to the vehicle.
Fuel, oils, etc.
You should use the fuels, oils and greases according to specifications as listed in the owner's manual.
Spare parts, accessories
For your own safety, use only spare parts and accessories approved by KTM. KTM accepts no liability for other products and any
resulting damage or loss.
Transport
Note
Danger of damageಘDanger of damage from accidental rolling of vehicle.
ದPark the vehicle on a surface that is as horizontal as possible and activate the parking brake.
Note
Fire hazardಘSome components (engine, radiator and exhaust system) get very hot when the engine is running.
ದDo not place the vehicle where there are flammable or explosive substances.
ದSwitch off the engine.
ದTurn the handlebof the fuel tap to the OFF position. (Figureb100013-10bP. 16)
ದUse straps or other suitable devices to secure the vehicle against accidents or falling over.
ದPull the hand brake lever, push the locking pawlbdown and release the hand brake lever. (Figureb100006-10bP. 14)
Environment
Offroad riding is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest. However, it is a potential prob-
lem for the environment and can lead to conflicts with other persons. But if you use your vehicle responsibly, you can ensure that such
problems and conflicts do not have to occur. To protect the future of offroad sport, make sure that you use your ATV legally, display
environmental consciousness, and respect the rights of others.

IMPORTANT NOTES 6
Rider training
If you have never ridden an ATV before, it is important that you participate in a driver training course before you ride the vehicle for
the first time.
A professional trainer will show you how to handle your ATV safely in various riding situations and on different terrain.
Your KTM dealer will be glad to advise you.

IMPORTANT NOTES 7

IMPORTANT NOTES 8
Overview of warning labels
100106-10

IMPORTANT NOTES 9
Notes/warning notes
Pay attention to the specified notes and warnings.
Info
Various notes and warning labels are attached to the vehicle. Do not remove any notes or warning labels. If they are missing,
you or others may not recognize dangers and may therefore be injured.
Grades of risks
Danger
Danger that leads immediately and certainly to severe and permanent injury or death.
Warning
Danger that will probably lead to severe and permanent injury or death.
Note
Danger of serious damage to machine or material.
Warning
Risk of environmental damage.
OWNER'S MANUAL
ದRead this owner's manual carefully and completely before making your first trip. It contains a lot of information and tips to help
you operate and handle your vehicle. Only then will you find out how to customize the vehicle ideally for your own use and how you
can protect yourself from injury. The owner's manual also contains important information on servicing the vehicle.
ದThe owner's manual is an important component of the vehicle and should be handed over to the new owner if the vehicle is sold.

VIEW OF VEHICLE 10
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
Vehicle view, front left
600148-10
1 Hand brake lever
2 Fuse box
3 Headlight
4 Front shock absorber
5 Right-hand brake caliper
6 Steering damper holder (steering damper is optional)
7 Front left shock absorber
8 Outside brake disk guard
9 Shift lever
10 Left footrest
11 Heel protector
12 Emergency OFF switch with rip cord
13 Clutch lever

VIEW OF VEHICLE 11
View of vehicle, rear right
600149-10
1 Light switch, electric starter button, ENG.bSTOPbswitch
2 Filler cap
3 Main silencer
4 Rear shock absorber
5 Rear sprocket with chain
6 Rear wheel eccentric element
7 Rear brake
8 Foot brake pedal
9 Compensating tank for coolant
10 Manifold
11 Top A-arm
12 Front right fender
13 Throttle lever
14 Ignition switch

LOCATION OF SERIAL NUMBERS 12
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
Chassis number
100002-10
The chassis numberbis stamped on the right side of the frame in the vicinity of the
upper control arm.
Type label
100034-10
The type labelbis located on the frame tube on the right in front of the radiator.
Key number
100089-10
The key numberbis indicated on thebKEYCODECARD.
Info
You need the key number to order a replacement key. Keep thebKEYCODECARD in
a safe place.
Engine number
100001-10
The engine numberbis stamped on the left side of the engine under the engine
sprocket.
Setting number, front shock absorber
100033-10
The setting numberbis stamped into the top of the shock absorber.

LOCATION OF SERIAL NUMBERS 13
Setting number, rear shock absorber
100032-10
The setting numberbis stamped into the top of the shock absorber.

OPERATING ELEMENTS 14
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
Clutch lever
100004-10
The clutch leverbis fitted on the left side of the handlebar.
Possible states
• Clutch lever in neutral position ದbIn this position, the engine is force-locked with
the gear and the starting circuit is interrupted. The electric starter does not turn
over when the electric starter button is pressed.
• Clutch lever pulled ದbIn this position, the force lock between the engine and the
gear is broken and the starting circuit is closed. The electric starter turns over
when the electric starter button is pressed.
The clutch is hydraulically operated and self-adjusting.
Reverse gear release lever
100005-10
The reverse gear release leverbis fitted on the left side of the handlebar.
Reverse gear can only be engaged when the reverse gear release lever is activated while
the vehicle is at a standstill.
Hand brake lever, parking brake
100006-10
The hand brake leverbis located on the right side of the handlebar and operates the
front brakes.
The hand brake lever is combined with the parking brake, which blocks the front
wheels to prevent the vehicle from rolling away.
To activate the parking brake, pull the hand brake lever, push the locking pawlbdown
and release the hand brake lever.
Possible states
• Hand brake lever in basic position ದbFront wheels are not blocked.
• Hand brake lever pulled and locked in position ದbFront wheels are blocked.
Throttle lever
100007-10
The throttle leverbis fitted on the right side of the handlebar.
The throttle lever is used to control the engine speed.

OPERATING ELEMENTS 15
Light switch
100011-10
The light switchbis fitted on the left side of the handlebar.
Possible states
• High beam on HI ದbLight switch is turned upwards. In this position, the high beam
and the tail light are switched on.
• Low beam on LO ದbLight switch is at the middle setting. In this position, the low
beam and tail lights are switched on.
• Lights off OFF ದbLight switch has been swiveled down. In this position, all lights
are switched off.
ENG.bSTOPbSwitch
100030-10
ThebENG.bSTOPbswitchbis fitted on the left side of the handlebar.
Possible states
• Ignition offbOFF ದbIn this position, the ignition circuit is interrupted, a running
engine stops, and the engine cannot be started.
• Ignition onbRUN ದbIn this position, the ignition circuit is closed and the engine can
be started.
Electric starter button
100029-10
The STARTbelectric starter button is fitted on the left side of the handlebar.
Possible states
• Electric starter button in basic position
• Electric starter button pressed ದbIn this position, the electric starter is actuated.
Ignition switch
100031-10
The ignition switchbis located on the instrument support.
Possible states
Ignition off ದbIn this position, the ignition circuit is interrupted, a running
engine stops, and a non-running engine will not start.
Ignition on ದbIn this position, the ignition circuit is closed and the engine
can be started.
Indicator lamp overview
400288-10
Possible states
Reverse gear indicator lampblights up red ದbReverse gear is engaged.
Ignition indicator lampblights up yellow ದbIgnition is switched on.
High beam indicator lampblights up blue ದbHigh beam is switched on.
Idle speed indicator lampblights up green ದbTransmission is switched
to idle.

OPERATING ELEMENTS 16
Emergency OFF switch with rip cord
100010-10
The emergency OFF switchbis mounted on the left in front of the fuel tank. A rip
cord is attached to the clipb. It can be attached to the clothing of the rider by means
of a carabiner.
The emergency OFF switch shuts the engine off if the rider falls off the vehicle.
Possible states
• Clip is pulled off ದbThe ignition circuit is interrupted, a running engine stops and a
non-running engine will not start.
• Clip is mounted ದbThe ignition circuit is closed and the engine can be started.
Opening filler cap
100012-10
ದPress release buttonb, turn filler cap counterclockwise and lift it free.
Closing filler cap
100012-11
ದReplace the filler cap and turn clockwise until the release buttonblocks in place.
ದCheck the fuel tank breatherbto ensure it is properly seated.
» If the fuel tank breather is at an angle or loose:
ದCorrectly mount the fuel tank breather.
Fuel tap
100013-10
The fuel tap is located on the right side of the fuel tank.
With the tap handlebon the fuel tap, you can open or close the supply of fuel to the
carburetor.
Possible states
• Fuel supply closed OFF ದbNo fuel can flow from the tank to the carburetor.
• Fuel supply open ON ದbFuel can flow from the tank to the carburetor. The fuel tank
empties down to the reserve.
• Reserve fuel supply open RES ದbFuel can flow from the tank to the carburetor. The
fuel tank empties completely.

OPERATING ELEMENTS 17
Choke
100014-10
The choke knobbis fitted on the left side of the carburetor.
Activating the choke function frees an opening through which the engine can draw
extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start.
Info
If the engine is warm, the choke function must be deactivated.
Possible states
• Choke function activated ದbThe choke lever is pulled out to the stop.
• Choke function deactivated ದbThe choke lever is pushed in to the stop.
Hot start button
100015-10
The hot start button (red)bis fitted on the left side of the carburetor.
Activating the hot start function frees an opening in the carburetor through which the
engine can draw extra air. This gives a leaner fuel-air mixture, which is needed for a
hot start.
Info
If the engine is cold, the hot start function must be deactivated.
Possible states
• Hot start function activated ದbThe hot start button is pulled out to the stop.
• Hot start function deactivated ದbThe hot start button is pushed in as far as possi-
ble.
Shift lever
100018-10
The shift leverbis mounted on the left side of the engine.
100017-10
The gear positions can be seen in the photograph.
The neutral or idle position is between the first and second gears.
Reverse gear can only be engaged with the vehicle at a standstill and the lever pulled.
Foot brake pedal
100016-10
The foot brake pedalbis located in front of the right footrest and operates the rear
wheel brake.

TIPS ON PUTTING INTO OPERATION 18
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
Advice on first use
Danger
Danger of accidentsಘDanger from inadequate traffic experience.
ದDo not use the vehicle if you are inexperienced or if you have consumed alcohol or drugs.
Warning
Danger of accidentsಘIncorrect assessment of riding situations.
ದThe vehicle may only be ridden by persons over the age of 16.
Warning
Danger of accidentsಘUnaccustomed handling of the ATV.
ದIf you have never ridden an ATV before, it is important that you participate in a driver training course before you ride the
vehicle for the first time.
ದA professional trainer will show you how to handle your ATV safely in various riding situations and on different terrain. Your
KTM dealer will be glad to advise you.
Warning
Risk of injuryಘRisk of injury by missing/inadequate protective clothing.
ದWear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the motorcycle.
Always wear protective clothing, which must be in perfect condition and meet legal requirements.
Warning
Danger of crashingಘImpairment of riding behavior due to different tire tread patterns on front and rear wheels.
ದThe front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.
Warning
Danger of accidentsಘCritical riding behavior due to inappropriate riding.
ದAdapt your riding speed to the road conditoins and your riding ability.
Warning
Danger of accidentsಘAccident risk caused by presence of a passenger.
ದYour vehicle is not designed to carry passengers. Do not ride with a passenger.
Warning
Danger of accidentsಘBrake system failure.
ದIf the foot brake pedal is not released, the brake linings drag permanently. The rear brake can fail due to overheating. Take
your foot off the foot brake pedal if you do not want to brake.
Warning
Danger of accidentsಘUnstable riding behavior.
ದDo not exceed the maximum permitted weight and axle loads.
Warning
Risk of misappropriationಘUsage by unauthorized persons.
ದNever leave the vehicle unattended while the engine is running. Secure the vehicle against use by unauthorized persons.
Always remove the ignition key.
Warning
Danger of accidentsಘInstable handling from loaded luggage.
ದThe vehicle is not designed to carry luggage. Do not attach luggage to the vehicle.
Warning
Danger of accidentsಘPoor recognizability of vehicle on hilly terrain and/or sand dunes.
ದAttach a safety flag to the vehicle.
Info
When using your vehicle, remember that others may feel disturbed by excessive noise.
ದMake sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop.
You receive a delivery certificate and the service record at vehicle handover.
ದBefore your first trip, read the entire operating instructions carefully.